US20050150229A1 - Method for operating a gas turbine - Google Patents
Method for operating a gas turbine Download PDFInfo
- Publication number
- US20050150229A1 US20050150229A1 US10/754,195 US75419504A US2005150229A1 US 20050150229 A1 US20050150229 A1 US 20050150229A1 US 75419504 A US75419504 A US 75419504A US 2005150229 A1 US2005150229 A1 US 2005150229A1
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- Prior art keywords
- exhaust gas
- turbine
- compressor
- gas turbine
- gas
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02C—GAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
- F02C7/00—Features, components parts, details or accessories, not provided for in, or of interest apart form groups F02C1/00 - F02C6/00; Air intakes for jet-propulsion plants
- F02C7/12—Cooling of plants
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E20/00—Combustion technologies with mitigation potential
- Y02E20/16—Combined cycle power plant [CCPP], or combined cycle gas turbine [CCGT]
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Control Of Turbines (AREA)
- Engine Equipment That Uses Special Cycles (AREA)
Abstract
Description
- This invention relates generally to the field of power generation, and more particularly, to operation of a gas turbine.
- Combined cycle power plants are well known in the art. A combined cycle power plant includes both a gas turbine-based topping cycle and a steam turbine or a steam rankine bottoming cycle that is driven by heat in the exhaust of the gas turbine. During startup of a combined cycle power plant from cold start conditions, the gas turbine portion of the plant necessarily must be started before the steam turbine portion. The term cold start is a relative term but is used herein to refer generally to conditions where the plant has not been operated for an extended time period, such as 48 hours, and where the boiler is not pressurized. During startup of a gas turbine having a single shaft-constant speed arrangement, there is a relatively rapid increase in the flow rate of the exhaust from the gas turbine as it accelerates to operating speed. Thereafter, the exhaust gas flow rate remains relatively constant except for the effect of compressor inlet guide vane modulation. After the gas turbine reaches operating speed, the temperature of the exhaust gas gradually increases as the firing temperature of the gas turbine is increased up to the level required to produce the desired power output. However, the rate of increase in load and temperature of the gas turbine exhaust is constrained by thermal transient stress limits in the components of the steam turbine and the balance of plant, including the heat recovery steam generator (HRSG) that is exposed to the hot exhaust gas stream. During startup, the startup temperature of the gas turbine exhaust is regulated to gradually heat and pressurize the HRSG. In a typical combined cycle plant, the gas turbine may be initially limited to about 20-30% rated power in order to maintain the exhaust at a sufficiently low temperature to maintain stresses within acceptable levels in the cold HRSG.
- The necessity to gradually heat a combined cycle power plant during startup reduces the overall efficiency of the plant and reduces the plant's ability to respond to rapidly changing power requirements. Furthermore, the operation of the gas turbine portion of the plant at less than full rated load may result in a level of gaseous emissions that exceeds regulatory or Original Equipment Manufacturers base load contractual requirements. In particular, it is known that the level of carbon monoxide (CO) produced in a gas turbine engine will increase as the firing temperature is decreased during part-load operation. Operation of the gas turbine portion of a combined cycle power plant at 20-50% rated load during the startup phase will often place the plant outside of emissions compliance limits. Not only does such operation have an undesirable impact on the local environment, but it may also have a negative financial impact on the owner or operator of the plant, since a plant revenue stream may be adversely impacted by operation outside of regulatory compliance limits. Accordingly, there is a strong incentive to reduce the startup time for a combined cycle power plant and to reduce the operation of the plant at non-compliance emissions points.
- The invention will be more apparent from the following description in view of the drawings that show:
-
FIG. 1 is a functional diagram of a combined cycle power plant having a gas turbine having a flow path conducting compressed air from an inlet upstream of the combustor to an outlet downstream of the turbine. -
FIG. 2 is a flow chart illustrating a method of opening inlet guide vanes to provide a flow of compressed air directed downstream of the turbine ofFIG. 1 . -
FIG. 3 is a graph illustrating the gross plant load versus time during the startup of a combined cycle power plant both with and without the use of a bypass flow path. -
FIG. 1 is a functional diagram of agas turbine 10. Major component of thegas turbine 10 include acompressor 12, acombustor 14 and aturbine 16. Thegas turbine 10 receivesambient air 18 through a set of inlet guide vanes 20. Theambient air 18 is compressed bycompressor 12 and delivered tocombustor 14 where it is used to combust a flow offuel 22 from afuel source 23 to producehot combustion gas 32. Thehot combustion gas 32 is delivered toturbine 16 where it is expanded to develop shaft power. Typically, theturbine 16 andcompressor 12 are connected to acommon shaft 24, which in turn may be connected to anelectrical generator 26. In a combined cycle plant, theexhaust gas 28 produced by thegas turbine 10 may be directed to an HRSG (not shown) of asteam turbine portion 60 of the plant. The aforementioned components of thegas turbine 10 are fairly typical of those found in the prior art, and other known variations of these components and related components may be used in other embodiments of the present invention. - In a conventional startup procedure, the loading on the
gas turbine 10 may be limited to 20% to 50% of a rated base load to insure that a sufficiently low exhaust temperature is maintained to avoid overheating a downstream HRSG. However, partial load operation may increase pollutant emission due to a decreased firing temperature inherent when operating at less than full load. In addition, at low loads, stability of the flame may be difficult to achieve as a result of the decreased firing temperature and a comparatively lower air to fuel ratio (AFR) as less fuel is provided per the same air volume that is provided at higher loads. To improve stability of the flame during start up, theinlet guide vanes 20 are typically closed to reduce a volume ofambient air 18 introduced into thecompressor 12. Consequently, a relatively smaller volume of acombustion portion 30 of compressed air is supplied by thecompressor 12 compared to a volume of thecombustion portion 30 exiting thecompressor 12 when thevanes 20 are open. As a result, the AFR in thecombustor 14 may be lowered, provided a volume offuel 23 supplied to thecombustor 14 is maintained. Therefore, in conventional gas turbines, theinlet guide vanes 20 are closed during startup to provide a lower AFR and achieve flame stability at partial loads. As a load on thegas turbine 10 is increased (for example, according to a desired loading schedule for gas turbine startup in a combined cycle plant), theinlet guide vanes 20 may be gradually opened until reaching a fully open position at a predetermined power level. - Contrary to the conventional technique of closing the inlet guide vanes during a startup period, the inventors have developed an innovative gas turbine operating method that includes opening, instead of closing, the inlet guide vanes during startup. Opening the inlet guide vanes has the advantage of increasing the temperature of air exiting the compressor, and consequently, a firing temperature in the combustor to achieve flame stability and reduced CO formation. However, with the inlet guide vanes being opened, a greater volume of compressed air will be provided by the compressor than is a volume of compressed air needed to support combustion in the combustor. An excess volume of compressed air, comprising, for example, a portion of the greater volume of compressed air exceeding the volume of compressed air needed to support combustion, is extracted upstream of the combustor and directed downstream of the turbine to combine with the turbine exhaust. Accordingly, an overall exhaust temperature of the gas turbine may be reduced by addition of excess air having a temperature relatively lower than a temperature of the exhaust gas exiting the turbine. As a result, the firing temperature (power level) may be maintained at a higher temperature (power) because the exhaust from the turbine is cooled, for example, to a temperature low enough to prevent damage to a downstream HRSG. Advantageously, the
gas turbine 10 may be operated at a power level sufficiently high to enable satisfying an emissions regulation by combining the excess compressed air with the exhaust gas. In addition, thegas turbine 10 may be scheduled to operate at a higher load relatively sooner than is possible in a conventional combined cycle plant. - To accomplish the foregoing, the
gas turbine 10 further includes abypass flow path 34 conducting anexcess portion 36 of the compressed air from aninlet 38 upstream of thecombustor 14 to anoutlet 42 downstream of theturbine 16. In one embodiment, theexcess portion 36 may be extracted frominlet 38 positioned in an early stage ofcompressor 12 for providing a comparatively cooler, lower pressureexcess portion 36 than may be available in a later stage of the compressor. For example, in acompressor 12 having stages numbering 1 through N, consecutively, from a lowest pressure stage to a highest pressure stage, theinlet 38 may be disposed in a stage having a stage number less than N/2. In a 19-stage compressor, theinlet 38 may be disposed in the 6th stage. Extractingexcess portion 36 from a lower pressure stage may be desired to minimize the pressure of theexcess portion 36 entering theexhaust gas 28. In a retrofit application, theexcess portion 36 may be extracted from a preexisting pressure tap, such as a bleed port in thecompressor 12, thereby reducing the need for extensive modifications. - The
bypass flow path 34 may further include an excessair control valve 40, such as a metering valve, for controlling the amount ofexcess portion 36 bypassed around thecombustor 14 andturbine 16. The excessair control valve 40 may be metered to deliver a controlled amount ofexcess portion 36 intoexhaust gas 28 downstream of theturbine 16 to produce a cooledexhaust 44. Accordingly, cooledexhaust 44 has a higher mass and a lower temperature than does the flow ofexhaust gas 28 leaving theturbine 16. The excessair control valve 40 may be responsive to avalve control signal 48 provided by acontroller 46. Thevalve controller 46 may control the excessair control valve 40 in response to temperature measurements provided bytemperature sensor 52 for measuring a temperature of theexhaust gas 28 andtemperature sensor 50 for measuring a temperature of the cooledexhaust 44. For example, in a retrofit application, an existing gas turbine controller may be modified to incorporate monitoring temperatures of theexhaust gas 28 and cooledexhaust 44 to generate avalve control signal 48 controlling the flow of theexcess portion 36 into theexhaust gas 28. In addition, other system parameters that are useful in controlling gas turbine operation, such as temperatures, pressures, or flow rates at other locations throughout the combined cycle plant, may be sensed by thecontroller 46 to generate a desired flow ofexcess portion 36 into theexhaust gas 28 via excessair control valve 40. In other retrofit applications,temperature sensor 50 may need to be installed in the flow of cooledexhaust 44 downstream from a point where theexcess portion 36 is combined with theexhaust gas 28. - The
controller 46 may be further configured to control an amount of fuel provided to thecombustor 14 via afuel metering valve 54. For example, the flow offuel 22 provided to thecombustor 14 may be controlled to achieve a desired combustion condition, such as a desired firing temperature, or air to fuel ratio in thecombustor 14. The flow offuel 22 may be adjusted depending on an amount ofexcess portion 36 bypassed around thecombustor 14 andturbine 16 and the amount ofair 30 provided to thecombustor 14. In addition, thecontroller 46 may be configured to control the position of the inlet guidesvanes 20, via an inlet guide vanes controlsignal 58, for example, in conjunction with an amount ofexcess portion 36 directed around thecombustor 12 andturbine 16. In an aspect of the invention, theinlet guide vanes 20 may be fully opened during start initiation, and the position of thevanes 20 adjusted after start initiation according to an amount ofexcess portion 36 bypassed. Accordingly, a desired operating condition, such as a desired air to fuel ratio in thecombustor 14, may be achieved. In yet another aspect, theinlet guide vanes 20 may be controlled in response to the exhaust gas temperature. -
FIG. 2 is aflow chart 70 illustrating an exemplary control method for opening theinlet guide vanes 20 to provide a flow ofexcess portion 36 directed downstream of the turbine ofFIG. 1 . In one form, thecontroller 46 may be configured to perform the actions shown in theflow chart 70. The control method may be initiated when thegas turbine 10 reaches a loading of 25% of a ratedbase load 72. Theinlet guide vanes 20 are opened 74 from their normally closed position to allow a larger volume of air to enter thecompressor 12 than is conventionally supplied. For example, theinlet guide vanes 20 may be opened to a maximum opened position, such as 0 degrees with respect to an incoming air flow.Excess portion 36 is then extracted 76 from thecompressor 12 and injected 78 downstream of theturbine 16. To maintain a desired firing temperature in thecombustor 14, the flow offuel 22 may be increased 80 in response to an increased volume of air flowing through the combustor as a result of opening the inlet guide vanes 20. The amount ofexcess portion 36 bypassed around thecombustor 14 andturbine 16 may be adjusted 82, for example, in a combined cycle system, to maintain a desired HRSG temperature curve. The flow offuel 22 is then adjusted to maintain a desired firing temperature responsive to a temperature of theexhaust gas 28, until the steam portion of theturbine 60 is brought up to full load. If thesteam turbine portion 60 has not reachedfull load 86, then the amount ofexcess portion 36 and the flow offuel 22 are continually adjusted 82, 84, if required. Once thesteam turbine portion 60 has reached full load, the excessair control valve 40 is closed 88 andnormal gas turbine 10 operation is resumed 90. - The startup of an exemplary combined cycle power plant having dual gas turbines,
GT 1 andGT 2, both with and without the use of anbypass flow path 34, is illustrated inFIG. 3 .Curve 100 shows the power output versus time using prior art procedures and equipment, whilecurve 102 shows power output versus time with thebypass flow path 34 activated and using the procedure described herein. The plant is started from shutdown conditions byfirst starting GT 1. The power level ofGT 1 is increased to a level above that which would otherwise be possible without the use ofbypass flow path 34, and preferably is increased as rapidly as possible to a power level where all emissions in the gas turbine exhaust are at their lowest levels or at a desired low level (on a ppm basis) for satisfying emissions regulations. During this time, the temperature of the cooledexhaust 44 into thesteam turbine portion 60 is kept within acceptable levels by the relatively coolerexcess portion 36. During this period, the excessair control valve 40 is metered to provide an appropriate flow ofexcess portion 36 to combine with theexhaust gas 28 so that the temperature of the cooledexhaust 44 does not exceed that which is acceptable for warming of an HRSG in thesteam turbine portion 60 and that which is used for startup under prior art procedures. - Accordingly,
GT 1 andGT 2 may operated at higher loads with correspondingly reduced emissions, sooner than is possible over the prior art (as can be seen by comparing respective operating points at D and J, for example). In the example ofFIG. 3 , the total plant startup time to full power is reduced from about 95 minutes to about 88 minutes, and the total power generated by the plant during the startup phase is increased by about one quarter (area under the respective curves) with use of thebypass flow path 34. Importantly, thegas turbine portion 12 can be operated at a power level sufficiently high so that the gas turbine exhaust emissions are at a desired low level at or close to their lowest concentration levels measured on a ppm basis. These lower emissions levels allow the operator to satisfy regulatory and contractual emissions commitments, thereby potentially further increasing the revenue generated by the plant and providing a reduced environmental impact. - While the preferred embodiments of the present invention have been shown and described herein, it will be obvious that such embodiments are provided by way of example only. Numerous variations, changes and substitutions will occur to those of skill in the art without departing from the invention herein. Accordingly, it is intended that the invention be limited only by the spirit and scope of the appended claims.
Claims (16)
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US10/754,195 US7124591B2 (en) | 2004-01-09 | 2004-01-09 | Method for operating a gas turbine |
US11/169,476 US20050235649A1 (en) | 2004-01-09 | 2005-06-29 | Method for operating a gas turbine |
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US10/754,195 US7124591B2 (en) | 2004-01-09 | 2004-01-09 | Method for operating a gas turbine |
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US11/169,476 Continuation-In-Part US20050235649A1 (en) | 2004-01-09 | 2005-06-29 | Method for operating a gas turbine |
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US7124591B2 US7124591B2 (en) | 2006-10-24 |
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